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GTI6 engine conversion

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welsh_ben
Ollie
Dans 306
309-gti6-turbo
AlexJ
curl666
WELSHPUG
Simon
roland rat
_Mike_
Ben C
racermike
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Post by racermike Tue 29 Jul 2008, 23:33

this morning ordered a pair of axle stands from work (so ill have a set of 4 then Very Happy ).

Started by jacking the car up and removing the front bumper, arch liners, headlight trims, front grille, headlamps, slam panel.

Next was the induction kit out of the way and then the top rad hose disconnected.

So this is how it looks after 2 hours work so far.

GTI6 engine conversion Front_10

Next was the induction kit out of the way and then the top rad hose.

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306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


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Post by racermike Wed 30 Jul 2008, 00:17

Lower rad hose disconnected, engine radiator removed,air con rad removed fans removed, battery disconnected, ecu unplugged, battery box removed, the two main engine/chassis loom plugs disconnected from offside inner wing.

GTI6 engine conversion Rads__10

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306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


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Post by racermike Wed 30 Jul 2008, 02:49

throttle cable now disconnected, fuel hoses disconnected, the earth under the battery box disconnected from the chassis and a couple of other cables that i could see were connected to the chassis.

so this is how it stands at the moment.

GTI6 engine conversion Wiringthrottledisconnected

GTI6 engine conversion Fuelhosesdisconnected

But im unsure if theres anything else to disconnect in the engine bay before put the car on axle stands on blocks so i think thats it for today.

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306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


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racermike@southwalespugs.net
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Post by Ben C Wed 30 Jul 2008, 03:15

have you disconnected the heater matrix hose, clutch cable, gear linkages
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Post by racermike Wed 30 Jul 2008, 03:25

is the heater matrix hose the one that goes to the top of the bulkhead i did look at that but havent done it no. saw the clutch cable i think is it the one on the right under the battry box position looks similar to the throttle cable.?

gear linkages thats something i dont have a clue on yet, do i not do dat from underneath. scratch

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306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


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Post by Ben C Wed 30 Jul 2008, 03:44

the heater matrix hose usuallye comes from the thermostat housing to the bulkhead. clutch cable will be easy to identify as it should be the only cable coming from an arm on the box also you might have a cable for the speedo wich will be on the box also. linkages can usually get to them from the top or underneath. any other things you need help with give me a shout im no mechanic but i do have a good understanding of it and i did the engine conversion on my 106 myself well with abit of help
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Post by racermike Wed 30 Jul 2008, 03:46

ok well after work 2moro if its dry will do the heater hoses, speedo cable and clutch cable then.

_____________________________________www.swfco.net____
306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


https://s185.photobucket.com/albums/x245/racermike306
racermike@southwalespugs.net
racermike@hotmail.co.uk
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Post by _Mike_ Wed 30 Jul 2008, 03:47

Great progess so far mate!!

Always good to see people getting on with a job Smile
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Post by roland rat Wed 30 Jul 2008, 04:21

what ive had an engine in and out and running in 8 hours so your slacking mate lol!

good progress though mate as you have to be careful with the bodywork on her

keep the updates coming
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Post by Simon Wed 30 Jul 2008, 04:25

roland rat wrote:what ive had an engine in and out and running in 8 hours so your slacking mate lol!

8 hours why so long lol!

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GTI6 engine conversion Gunge210
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Post by racermike Wed 30 Jul 2008, 04:29

haha but you guys know wot ur doin, i make it up as i go along lol. clown

im putting the bolts and stuff into bags and labelling thrm so i know where they go. and labelling cables/hoses etc. im taking my time coz i dont want to damage/break anything.

_____________________________________www.swfco.net____
306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


https://s185.photobucket.com/albums/x245/racermike306
racermike@southwalespugs.net
racermike@hotmail.co.uk
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Post by roland rat Wed 30 Jul 2008, 07:20

racermike wrote:haha but you guys know wot ur doin, i make it up as i go along lol. clown

im putting the bolts and stuff into bags and labelling thrm so i know where they go. and labelling cables/hoses etc. im taking my time coz i dont want to damage/break anything.

good approach mate Smile

i was lucky while doing the last engine swap on my mates gti-6 as i had my 306 to check to if it didnt look right lol!
roland rat
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Post by WELSHPUG Wed 30 Jul 2008, 10:02

8 hours included chippy and about half a dozen coffee stops Laughing :p
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Post by racermike Wed 30 Jul 2008, 10:07

well if ash/welsh pug fancy coming down plenty of biscuits and tea available for the 9/10th august to help me drop the engine out i wouldnt say no lol. holpfully the 16/17th then dropping the gti6 in. then feel free to come down btw.

_____________________________________www.swfco.net____
306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


https://s185.photobucket.com/albums/x245/racermike306
racermike@southwalespugs.net
racermike@hotmail.co.uk
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Post by curl666 Wed 30 Jul 2008, 23:21

Some good progress so far!

I too took the same approach of labeling every bolt/nut and pipe I took off when I replaced the headgasket.

It was the first big job Id done on my car, and i too have no previous mechanical experience.

The first time I spent ages on it, the car was off the road for some time, just labeling, taking it really slow just to be sure. But then I ended up doing it again in a couple of hours!

Its the best way to learn!
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Post by roland rat Thu 31 Jul 2008, 04:34

would love to mate but ive got to fit the new bonnet on the china plus there's a certain 309 that needs picking up Cool
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Post by Simon Thu 31 Jul 2008, 04:42

roland rat wrote:would love to mate but ive got to fit the new bonnet on the china plus there's a certain 309 that needs picking up Cool

priorities first Smile

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GTI6 engine conversion Gunge210
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Post by racermike Fri 01 Aug 2008, 04:42

ok so this evening i have taken the clutch cable off the gearbox, unplugged the speedo cable, disconnected PAS hose, disconnected heater matrix hoses, taken two gear linkage roads off but the larger one i cant get at very easy to take off so will do that from underneath i think.


Last edited by racermike on Fri 01 Aug 2008, 06:02; edited 1 time in total

_____________________________________www.swfco.net____
306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


https://s185.photobucket.com/albums/x245/racermike306
racermike@southwalespugs.net
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racermike
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Post by racermike Fri 01 Aug 2008, 05:58

i think this is all i have to do now before im ready to lift the engine out. correct me if ive missed anything.

Disconnect the top hose on the power steering pump from the reservoir. (DONE). Unbolt the connector to the high pressure hose at the subframe join leaving this pipe connected to the pump and the engine.

Remove the brake master cylinder and remove the hose going from the cam driven pump to the brake servo.

Next up unbolt the cat from the manifold and disconnect the lambda sensor at the black and red conector.

remove both driveshafts from the gearbox. There are 2 routes here. Route 1 is to fully remove both shafts in the usual way completely from the vehicle. Route 2 is to release the wishbone ball joint and just pull the shaft free of the box leaving it still bolted into the hub (tie them up to the underside of the car to keep the joint together).

any more advice appreciated.

_____________________________________www.swfco.net____
306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


https://s185.photobucket.com/albums/x245/racermike306
racermike@southwalespugs.net
racermike@hotmail.co.uk
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Post by WELSHPUG Fri 01 Aug 2008, 07:25

don't need to remove the master cylinder.
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Post by racermike Fri 01 Aug 2008, 07:43

WELSHPUG wrote:don't need to remove the master cylinder.

ok thanks for that. as i had no idea how to do this would have to refer to the trusty haynes. scratch


Last edited by racermike on Fri 01 Aug 2008, 07:49; edited 1 time in total

_____________________________________www.swfco.net____
306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


https://s185.photobucket.com/albums/x245/racermike306
racermike@southwalespugs.net
racermike@hotmail.co.uk
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Post by Simon Fri 01 Aug 2008, 07:47

that will be a pain to bleed through the the abs pump wont it?

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Post by WELSHPUG Fri 01 Aug 2008, 07:52

not particularly, but then there's no need to remove it!
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Post by racermike Mon 04 Aug 2008, 05:52

after i finished work today started to get the car off the ground.

GTI6 engine conversion Axlestands

front wheels off next b4 i forget lol.
I still need to get the front up more. to make it easier to get under the car.


Last edited by racermike on Mon 04 Aug 2008, 09:08; edited 2 times in total

_____________________________________www.swfco.net____
306 XSI with GTI6 engine conversion
Meguiars top 25 french cars 2008


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racermike@southwalespugs.net
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Post by _Mike_ Mon 04 Aug 2008, 05:58

Wont be long now till the engines out Very Happy

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